Multi-part air duct for a motor vehicle, method for producing an air duct of this type, and motor vehicle having an air duct of this type

ABSTRACT

A multi-part air duct ( 10 ) for a motor vehicle has a lower foam part ( 11 ), an upper foam part ( 12 ), and lateral injection moldings ( 13, 14 ). The injection moldings ( 13, 14 ) connect the lower foam part ( 11 ) to the upper foam part ( 12 ) on both sides.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority under 35 USC 119 to German Patent Appl. No. 10 2016 117 058.5 filed on Sep. 12, 2016, the entire disclosure of which is incorporated herein by reference.

BACKGROUND 1. Field of the Invention

The invention relates to a multi-part air duct for a motor vehicle. The invention further relates to a method for producing an air duct, and to a corresponding motor vehicle with such an air duct.

2. Description of the Related Art

Deviations from the thermodynamic cycle process in an internal combustion engine give rise to waste heat that is discharged to the walls of the combustion chamber and the cylinder. An excessive operating temperature can, however, promote separation of the lubricating film or burning of the valves, and thus damage the engine. A wide variety of cooling systems for removing heat produced in internal combustion engines are known.

Motor vehicles of the prior art have different types of air ducts. In the present context, this should be understood as meaning all parts of the vehicle that determine the movement direction of the air and that establish a flow connection between air inlet openings and individual cooling components—for example heat exchangers of various cooling circuits of the motor vehicle.

DE 10 2009 031 746 A1 describes a cooling-air duct device for a motor vehicle that is arranged in front of the radiator with respect to the direction of travel of the vehicle. The cooling-air duct device of DE 10 2009 031 746 A1 has a first duct component and a second duct component arranged upstream of the first duct component and is composed of a material that is relatively easy to deform.

SUMMARY

The invention provides a multi-part air duct for a motor vehicle, a method for producing an air duct, and a motor vehicle.

The invention relates to a multi-part air duct with injection moldings on the sides and of foam parts above and below. The resulting product is lightweight and has the advantage of increased packing density for transport and thus better logistics.

The injection moldings can be joined to the foam parts by a clip connection and spring elements. Snap elements of this type can be produced from thermoplastics that are suitable for the injection molding, without significant additional expenditure on materials and production, and provide structural freedom.

The lower foam part can be equipped with film hinges to facilitate the transport and assembly process. The upper foam part may be formed so that back flow of air is avoided as a result of the foam part bearing against the radiator externally.

One exemplary embodiment of the invention is illustrated in the drawings and is described in more detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a first perspective view of an air duct according to the invention.

FIG. 2 is a second perspective view of the air duct.

FIG. 3 shows a first detail of the air duct.

FIG. 4 shows a second detail of the air duct.

FIG. 5 shows a third detail of the air duct.

FIG. 6 is a first perspective view of a lower foam part of the air duct.

FIG. 7 is a second perspective view of the lower foam part

FIG. 8 is in longitudinal section a motor vehicle according to the invention.

DETAILED DESCRIPTION

When viewed in combination, FIGS. 1 and 2 illustrate the basic structural features of an air duct 10 according to the invention. Based on its intended position in a motor vehicle, this air duct 10 comprises a lower foam part 11, an upper foam part 12, and lateral injection moldings 13, 14 that connect the lower foam part 11 to the upper foam part 12 on both sides.

FIGS. 3, 4 and 5 illustrate the snap connection between the upper foam part 12 on one side and the injection molding 14 shown in FIG. 1 on the right—and thus in FIG. 2 on the left—on the other side. FIGS. 3 and 4 show a snap hook 16 that can be expanded resiliently by pushing in the upper foam part 12. In this way, after being pushed in completely, the upper foam part 12 is tensioned elastically against a projection formed in the injection molding 14. As a result, a force-fitting and form-fitting connection arises between the foam part 12 and the injection molding 14.

The detail of FIG. 5 highlights one of the clips 15 used in the upper region of the air duct 10. The clip 15, in its end position (shown in the drawing), connects the upper foam part 12 and the injection molding 14 in a further direction of action in a form-fitting manner. However, other joining methods—for example screwing, clipping, clamping, or otherwise joining by pressing on or in within the meaning of DIN 8593-3—suitable for the connecting partners 11, 12, 13, 14 may be used, without departing from the scope of the invention.

FIG. 6 shows the lower foam part 11 on its own. Film hinges 17 extend parallel to one another and allow the lower foam part 11 to twist between the alternative configurations 21, 31 indicated in FIG. 7 can be seen.

Finally, FIG. 8 illustrates the design of the upper foam part 12 on the basis of its intended installation position in the motor vehicle 20). A bulge 19 can be seen in the upper region of the part and permits the air duct 10 to bear directly externally against the radiator 18 during production. 

What is claimed is:
 1. An air duct for a motor vehicle, comprising: a lower foam part; an upper foam part; and lateral injection moldings that connect the lower foam part to the upper foam part on both sides.
 2. The air duct of claim 1, further comprising snap elements that include clips and/or snap hooks, and the snap elements connect the injection moldings to the lower foam part and to the upper foam part.
 3. The air duct of claim 1, wherein the lower foam part comprises hinges.
 4. The air duct of claim 1, wherein the upper foam part bears against a radiator of the motor vehicle externally.
 5. A method for producing an air duct, comprising: forming a lower foam part and an upper foam part, casting injection moldings, and joining the lower foam part to the upper foam part on both sides by the injection moldings.
 6. The method of claim 5, wherein the joining is performed by pressing on clips.
 7. The method of claim 6, further comprising packing and transporting the lower foam part, the upper foam part and the injection moldings after the foaming and casting and before the joining.
 8. The method of claim 5, wherein the packing comprises folding the lower foam part by hinges, in particular film hinges.
 9. A motor vehicle, comprising a radiator, and the air duct of claim
 1. 10. The motor vehicle of claim 9, wherein the air duct bears against a radiator externally by means of the upper foam part. 